Last year the fuel pump fuse on my Mk1 focus would blow every so often, a simple change of the fuse and everything was fine. The fuse is now blowing more and more frequently and even when replacing the fuse if i try to start it back up immediately it just blows that fuse - I have to leave it at least 30 minutes before changing the fuse and starting her up and all is fine.

Obviously this is hugely inconvenient and I have read many of the topics on this subject but to be clear is a new fuel pump my only option?

A fuse blows for a reason and simply replacing it every time is not a fix because one time it may not be the fuse that blows but the pump. The fuse should only be replaced once the fault has been found especially with being used with highly flammable liquid.

The fuse is there to regulate the draw on power. If it rises above a certain point, the fuse blows. It's a simple way to protect expensive components like fuel pumps. However, the fact that it's blowing so often would suggest that it's trying to draw more power than Ford say it requires. Why is that? Is it partially seized? You'll have to have a look to find out. Is it diesel or petrol?

Your fuel pump is located in the fuel tank. To change the fuel pump it is necessary to remove the fuel tank.

Your problem is most likely caused by a defective fuel pump. You could first check the wiring for any damaged insulation or punctures. If the wiring is in good condition your only option is to install a new fuel pump.

Your problem is most likely caused by a defective fuel pump. You could first check the wiring for any damaged insulation or punctures. If the wiring is in good condition your only option is to install a new fuel pump.

Looking at a schematic for a Zetec SE 1999 Focus, the only component between the fuse box and the pump is an inertia switch. I have no idea what it does, but it might be worth having a look at that. Although it looks like a simple switch, so I'd be surprised if that was the issue. Is it Fuse F12 that keeps blowing?